Automated Welding
Automated welding involves using mechanical or electronic means to control welding conditions such as welding current, arc length, filler wire, or electrode feed, as well as travel speeds. Movement and guidance of the electrode, torch or welding head along the line of weld can be similarly controlled.
The advantages of automated welding are numerous. A less experienced operator can handle the welding machine and have satisfactory end results. A smaller percentage of welding electrodes is lost in stub ends. A much shorter arc is uniformly maintained by the automated welding process than is possible by a manual operator. A much higher current can be used with a given size of welding wire to produce better fusion. A much higher welding speed can also be obtained. During the automated welding process, welding is continuous from the beginning to the end of the seam, thereby eliminating intermediate craters unavoidable in manual work. The elimination of craters makes for a stronger, more homogenous, better weld for retaining liquids under pressure. Welding wire in coils for the automated welding process, though more expensive, provides for nearly continuous welding with either ac or dc automatic equipment.
Today, companies are spending top dollar in order to automate or semi-automate their welding and assembly lines.
Welding automation can be broken down into two essential categories: semi-automatic automated welding and fully automatic automated welding. In semi-automatic welding, an operator physically loads the parts into the welding fixture. A weld controller then maintains the welding process, motion of the torch, and stillness of the parts to predetermined parameters. After the weld is completed, the operator removes the completed assembly and the process begins again.
In fully automatic welding, a custom machine, or series of machines, loads the workpiece, guides the part or torch into position, completes the weld, scrutinizes the value of the joint and unloads the finished product. Further "part in place" and final product quality checks may also be calculated into the machine if required. Depending on the procedure, a machine operator may be necessary.
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